System and method for controlling and programming the production of a ball of thread

ABSTRACT

Described is a control and programming system and method for producing a ball of thread having a plurality of stretches with different colors along the longitudinal direction with a ball winding machine comprising: a device for acquiring the chromatic characteristics of the thread connected to a respective control unit, a device for moving the thread towards the ball winding machine and a device for cutting the thread.

This invention relates to the field of producing balls of thread-liketextile material, such as for example but without limiting the inventioncotton, wool, silk, yarns of mixed natural and synthetic materials.

More specifically, the invention relates to a new control andprogramming system for producing a ball of thread by a using a ballwinding machine. This invention also relates to a method for controllingand programming a system for producing a ball of thread.

Lastly, the invention relates to a ball winding machine comprising oneor more systems for controlling and programming the production of a ballof thread.

There are currently various prior art methods for producing balls ofthread-like textile material.

The term ball used hereinafter in the description and in the claimsmeans a continuous portion of thread-like textile material wound in amultiplicity of turns or windings relative to at least one axis ofrotation shared by all the turns.

The various windings may be made in turn around at least one collectingdevice.

If the thread to be wound to produce the ball has different coloursalong the longitudinal direction it is not possible, with the prior artsystems, to determine precisely which is the initial colour and which isthe final colour. More specifically, it is not possible to determine andcontrol the ball winding machine in such a way that the initial colourand the final colour are the same.

In practice, with the prior art systems there is no possibility ofcontrolling and programming in a systematic manner the initial and finalcolour of a predetermined ball of thread being made.

All the systems and methods currently known therefore have majordrawbacks.

More specifically, an important, but not unique, drawback is due to thefact that it is not possible to determine before completing the ballwhich is the final colour of the ball.

In detail, this lack of determination is rather disadvantageous for thefinal user of the ball since it creates uncertainty in the processing.

For example, using coloured balls made with prior art systems it is notpossible to produce two textile items (for example socks) which areidentical; in fact, since each ball is different, the end product willalso be different.

If, on the other hand, the end user wishes to obtain two perfectlyidentical products from the point of view of the colours, a waste ofmaterial is inevitably generated.

An aim of this invention is, therefore, to provide a system forcontrolling and programming production of a ball of thread having aplurality of stretches with different colours “a”, “b”, “c” along thelongitudinal direction which allows the drawbacks of the known methodsand balls to be overcome.

More specifically, an aim of this invention is to provide a system forcontrolling and programming production of a ball of thread having aplurality of stretches with different colours “a”, “b”, “c” along thelongitudinal direction so as to allow the production of a ball with awith a predetermined initial colour and a predetermined final colour,for example the same colour.

Another important aim is to provide a method for controlling andprogramming the production of a ball of thread having stretches ofdifferent colours along the relative longitudinal direction so as toobtain a ball with a predetermined initial colour and a predeterminedfinal colour, for example the same colour.

According to the system and method of this invention it is possible toproduce a series of balls in sequence all sharing the fact that theyhave the initial and final colour predetermined beforehand by themanufacturer. A further aim of the invention is to provide a ballwinding machine comprising a plurality of control and programmingsystems in order to produce in parallel a multiplicity of balls, allcontrolled and programmed in such a way as to obtain the predeterminedinitial and final colour, for example the same colour.

This invention describes a control and programming system for producinga ball of thread having a plurality of stretches with different coloursalong the longitudinal direction using a ball winding machine, thesystem comprising a device for acquiring the chromatic characteristicsof the various stretches of thread connected to a respective controlunit, a device for moving the thread towards the winding head of a ballwinding machine and a device for cutting the thread.

Advantageously, the system also comprises means for supporting thethread, for maintaining the same in a predetermined position relative tothe chromatic detection device.

Advantageously, the system also comprises means for positioning theacquisition device to achieve in an easy and certain manner the focusingthereof relative to the thread.

Advantageously moreover, the device for moving the thread comprises anozzle fed with compressed air.

Advantageously, the cutting device comprises a mechanical cutter.

Preferably, the device for acquisition of the chromatic characteristicsof the thread comprise a video camera, a camera, a photometer, ascanning sensor or a spectrophotometer.

This invention also relates to a method for controlling and programmingthe production of a ball of thread having stretches of different coloursalong the longitudinal direction, comprising the following operatingsteps:

-   -   programming the system in such a way as to learn, by means of        the acquisition device, the type of stretch of colour (for        example “a”) selected as initial colour of the ball, and the        interval of operation after which to activate the thread cutting        device,    -   preparing the thread in a winding head of a ball winding machine        located downstream of the system in such a way that the selected        colour “a” is the first to be wound on the ball,        -   activating the winding head,        -   activating the cutting device after the predetermined            operating interval and when the selected point “X” of the            next stretch of colour “a” is located at the cutting device.

Advantageously, according to the method, the movement device is keptactuated not only during the ball winding steps but also during andafter the cutting step to hold in position the thread and facilitate themovement towards the winding head of the ball winding machine.

This invention also provides a ball winding machine comprising aplurality of control and programming systems for producing a ball ofthread as described.

Advantageously moreover, the operation of the ball winding machine iscontrolled according to the method described.

Further features and details of a preferred, non-limiting embodiment ofthe invention will be described in more detail below with reference tothe accompanying drawings, in which:

FIG. 1 illustrates a first schematic view of a possible embodiment of acontrol and programming system according to this invention;

FIG. 2 illustrates a second schematic view of the embodiment of FIG. 1,

FIG. 3 is a schematic view of a ball winding machine comprising a seriesof systems according to this invention and illustrated in FIGS. 1 and 2,

FIG. 4 is a schematic view of two operating times in the operation of acontrol and programming system according to this invention.

As illustrated in FIGS. 1 to 4, the numeral 1 denotes a control andprogramming system for producing a ball of thread 10 using a ballwinding machine 20.

More specifically, this invention relates to the production of a ball ofthread 10 which has on its longitudinal extension a series of stretches(at least two) coloured in a different way “a”, “b”, “c” along alongitudinal direction. Advantageously, but not necessarily, the seriesof coloured stretches “a”, “b”, “c” is repeated in a systematic andequal manner along the entire length of the thread 10.

The system 1 comprises in its basic embodiment a device 2 for acquiringthe chromatic characteristics “a”, “b”, “c” of the thread 10.

Merely by way of an example, the acquisition device 2 may comprise avideo camera, a camera, a photometer, a scanning sensor or aspectrophotometer, or any other device 2 designed to recognise a colourof the thread 10 in question.

The system 1 also comprises a device 3 for moving the thread 10 towardsa winding head (not illustrated since of known type) of a ball windingmachine 20. The thread is also being unwound from a source for feedingthe thread 10 (also not illustrated since of known type).

The movement device 3 preferably comprises a compressed air nozzle whichuses, precisely, compressed air for moving the thread 10 towards thewinding head located downstream of the system 1 in the direction of thearrow F.

By modulating the air entering the above-mentioned nozzle 3 it ispossible to determine the speed of sliding of the thread 10 inside itstarting from a value of zero metres per second, that is to say,stationary relative to the nozzle.

Advantageously, the nozzle 3 is kept in position through a respectiverigid support 8.

The system 1 also comprises a device 4 for cutting the thread 10positioned advantageously downstream of the movement device 3 and thevideo acquisition device 2, and upstream of the above-mentioned windinghead.

The cutting device 4 can, preferably, comprise a mechanicalguillotine-type cutter.

It will be understood that any cutting device 4 which is able to cut thethread 10 in a clean and precise manner can perform the same functionwithout thereby limiting the scope of protection of this invention.

In order to make the focusing of the thread 10 by the acquisition device2 easier, the system 1 may comprise suitable means 6 for supporting thethread 10.

In this way, it is possible to keep the thread 10 in a predetermined andfixed position relative to the acquisition device 2.

Again so as to facilitate the focusing of the acquisition device 2, thesystem comprises means 5 for positioning the acquisition device 2.

For example, the latter may comprises longitudinal guide means on twomovement axes.

The system 1 described above is preferably enclosed within a containmentbody 7.

In operation, a system 1 according to this invention comprises the 20following operating steps:

-   -   programming the system 1 in such a way as to learn, by means of        the acquisition device 2, the type of stretch of colour “a”        selected as initial colour of the ball, and the interval of        operation after which to activate the cutting device 4,    -   preparing the thread 10 in a winding head of a ball winding        machine 20 located downstream of the system 1 in such a way that        the colour “a” is the first to be wound on the ball,    -   activating the winding head,        By way of an example, the interval of operation may be        calculated by checking the actual length of the thread 10        already wound on the ball, the number of windings of the ball in        production, a unit of time, or in any case by measuring any        operating parameter which allows the actual approach of the        stretch of selected colour “a” to be detected,

Advantageously, once the thread 10 has been cut in the position derivedfrom the calculations described above the movement device 3 is keptactuated.

In this way, the end of the thread 10 distal from the winding head iskept stationary and extracted from the movement device 3, thusfacilitating the approach towards the winding head, for example by auser or an automatic system, to start the production of a new ball.

For clarity and completeness of description, and with reference inparticular to FIG. 4, an example is given of the operating cycle of asystem 1 according to this invention.

The following data must be known: total length of the thread 10 to bewound, length of the stretch of colour selected as initial and finalcolour of the ball in production “a”.

It should be noted that it is not necessary to know any data relative tothe length and to the type of colours between those not selected (“b”and “c” in FIG. 4) as initial and final colours of the ball.

An operation interval t1 is set, corresponding, for example, to 1000turns or 200 metres or 30 seconds.

At the initial time t0 the user (or the automatic system) fixes the endof the colour “a” to the winding head.

The winding head is actuated and produces the respective ball for thetime t1.

At the time t1 the winding head performs, advantageously, a slowing downand the video acquisition device 2 is enabled.

The slowing down may be advantageous to improve the acquisition by theacquisition device 2, however it may be not necessary depending on thequality of resolution and sensitivity of the device 2.

When the acquisition device 2 detects the stretch of colour selected “a”it sends a signal to the cutting device 4 which proceeds with thecutting when reaching the selected point “X”.

The ball winding machine proceeds, ending the winding of the length ofthread 10 just cut by the cutting device.

At this point, the user may again fix the end of colour “a” to thewinding head for producing a new ball, which is also characterised inthat it starts with a stretch of colour “a” and ends with the samecolour “a”.

Advantageously, by suitable control of the movement device 3, it ispossible to move the end of the thread 10 towards the winding head insuch a way as to facilitate the work of the user.

A further aspect according to the invention, shown in FIG. 3, is a ballwinding machine 20 comprising a plurality of control and programmingsystems 1 as described previously and associated with respective windingheads, not shown because they are of known type and not significant forthe purpose of this invention.

Preferably, the above-mentioned machine will be characterised by anoperation as described above.

Finally, it is clear that this invention may be modified, added to oradapted in ways obvious to technicians in the field, without therebydeparting from the protective scope of the appended claims.

More specifically, it is understood that by using a system according tothis invention is possible to program the entire composition of a ball(or a series of balls) both in terms of number and length of theindividual stretches of different colours.

1. A control and programming system for producing a ball of thread for aball winding machine, the thread having a plurality of stretches withdifferent colours along the relative longitudinal direction,characterised in that it comprises: a device for continuously acquiringthe chromatic characteristics of the thread connected to a respectivecontrol unit, a device for moving the thread towards the ball windingmachine and a device located downstream at least of the acquisitiondevice.
 2. The system according to claim 1, also comprising means forsupporting the thread, to keep the thread in a predetermined and fixedposition relative to the chromatic acquisition device.
 3. The systemaccording to claim 1, also comprising means (5) for positioning theacquisition device to achieve the focusing of the thread.
 4. The systemaccording to claim 1, wherein the device for moving the thread comprisesa nozzle fed with compressed air.
 5. The system (1) according to claim1, wherein the cutting device comprises a mechanical cutter.
 6. Thesystem according to claim 1, wherein the acquisition device comprise avideo camera, a camera, a photometer, a scanning sensor or aspectrophotometer.
 7. A method for controlling and programming theproduction of a ball of thread having stretches of different coloursalong the longitudinal direction comprising the following operatingsteps: programming a system in such a way as to learn, by means of anacquisition device, the type of stretch of colour selected as initialcolour of the ball, and the interval of operation after which toactivate a cutting device, preparing the thread in a winding head of aball winding machine located downstream of the system in such a way thatthe colour is the first to be wound on the ball, activating the windinghead, activating the cutting device after the predetermined operatinginterval and when the selected point of the next stretch of colour islocated at the cutting device.
 8. The method according to claim 7,wherein the movement device is kept actuated not only during the ballwinding steps but also during and after the cutting step to hold inposition the thread and facilitate the movement towards the winding headduring production of the next ball.
 9. A ball winding machine comprisinga plurality of control and programming systems according to claim
 1. 10.(canceled)
 11. The system according to claim 2, also comprising meansfor positioning the acquisition device to achieve the focusing of thethread.
 12. The system according to claim 11, wherein the device formoving the thread comprises a nozzle fed with compressed air.
 13. Thesystem according to claim 12, wherein the cutting device comprises amechanical cutter.
 14. The system according to claim 13, wherein theacquisition device comprise a video camera, a camera, a photometer, ascanning sensor or a spectrophotometer.
 15. The system according toclaim 2, wherein the device for moving the thread comprises a nozzle fedwith compressed air.
 16. The system according to claim 2, wherein thecutting device comprises a mechanical cutter.
 17. The system accordingto claim 2, wherein the acquisition device comprise a video camera, acamera, a photometer, a scanning sensor or a spectrophotometer.
 18. Thesystem according to claim 3, wherein the device for moving the threadcomprises a nozzle fed with compressed air.
 19. The system according toclaim 3, wherein the cutting device comprises a mechanical cutter. 20.The system according to claim 3, wherein the acquisition device comprisea video camera, a camera, a photometer, a scanning sensor or aspectrophotometer.